CN116890489A

CN116890489A - Sound absorption and insulation pad for vehicle, manufacturing method and vehicle

Info

Publication number: CN116890489A
Application number: CN202310742760.9A
Authority: CN
Inventors: 王凯; 吴迪; 延伟华; 李飞跃
Original assignee: Zhiji Automobile Technology Co Ltd
Current assignee: Zhiji Automobile Technology Co Ltd
Priority date: 2023-06-21
Filing date: 2023-06-21
Publication date: 2023-10-17

Abstract

The application relates to the technical field of vehicle sound insulation, in particular to a vehicle sound absorption and insulation pad, a manufacturing method and a vehicle. The sound absorption and insulation pad for the vehicle comprises a first sound absorption layer, a sound insulation layer and a second sound absorption layer, wherein the first sound absorption layer and the second sound absorption layer are respectively and fixedly arranged on two sides of the sound insulation layer, the sound insulation layer is made of superfine fiber hard felt made of polyethylene terephthalate superfine fibers, and low-melting-point polyethylene terephthalate is mixed in the polyethylene terephthalate superfine fibers. Solves the technical problems that the existing ABA type sound insulation pad has bad smell, heavy weight and improved sound absorption and insulation effect.

Description

Sound absorption and insulation pad for vehicle, manufacturing method and vehicle

Technical Field

The application relates to the technical field of vehicle sound insulation, in particular to a vehicle sound absorption and insulation pad, a manufacturing method and a vehicle.

Background

Currently, the development of interior sound insulation mats for vehicles mainly solves two main problems: for sound absorption and sound insulation, the sound absorption is mainly to absorb and consume incident sound energy and reduce reflected sound, so that noise in a volume is reduced, namely, the noise is isolated by absorbing the sound, and the sound is usually absorbed by one or more of porous materials such as felt, sponge and the like. For sound insulation, the sound insulation structure is mainly used for blocking sound, reducing noise transmission, enabling noise environment to be separated from environment needing silence, namely, isolating noise is achieved through blocking sound, materials with large weight and high density are usually selected, materials such as felt, EVA and the like are usually selected, the materials are heavy, and smell is large. The problem of mutual restriction exists between the sound absorption and the sound insulation, so that the sound absorption of the middle and high frequency is poor when the sound insulation of the middle and high frequency is good, and the overall acoustic performance of the part is influenced.

Typical sound insulation mat structures are single layer sound absorbing cotton, traditional (spring-mass structures), double layer dissipative (soft and hard felt) structures, multi-layer ABA type structures. The single-layer sound-absorbing cotton structure has good sound-absorbing performance and almost no sound-insulating performance; the traditional sound insulation pad (spring-mass structure) has poor sound absorption performance, good sound insulation performance, poor smell and VOC (volatile organic compound) and heavier weight; the double-layer dissipative sound insulation pad structure has both sound absorption and insulation, but the sound absorption performance is obviously reduced if the hard layer is compressed to be thinner, and the sound insulation performance is obviously reduced if the hard layer is compressed to be thicker; the ABA type structure has both sound absorption and insulation, and compared with the traditional type structure, the ABA type structure has equivalent acoustic performance in the whole vehicle and can replace the traditional type structure.

The commonly used ABA type acoustic structure is a waste textile felt + EVA + waste textile felt or a waste textile felt + non-perforated high gram weight PE film + waste textile felt structure, which although acoustically performs well, can replace traditional ones, but the odor and VOC are also much worse and heavier. Accordingly, the prior art is subject to further development.

Disclosure of Invention

The application provides a sound-absorbing and sound-insulating pad for a vehicle, a manufacturing method and the vehicle, and aims to solve the technical problems that an existing ABA type sound-insulating pad is poor in smell, heavy in weight and poor in sound-absorbing and sound-insulating effect.

According to a first aspect of the present application, there is provided a sound-absorbing and insulating mat for a vehicle, comprising a first sound-absorbing layer, a sound-insulating layer and a second sound-absorbing layer, the first sound-absorbing layer and the second sound-absorbing layer being fixedly disposed on both sides of the sound-insulating layer, respectively, characterized in that the sound-insulating layer is a super-fine fiber hard felt made of PET super-fine fibers, the super-fine fiber linear density is between 0.1 and 1.0D, wherein

The PET superfine fiber is mixed with a low-melting-point PET fiber.

Alternatively, in some embodiments of the present application, the first sound absorbing layer is a first ultrafine fibrous soft felt, the first ultrafine fibrous soft felt being a soft felt made of the PET ultrafine fibers, wherein

The first sound absorbing layer and the sound insulating layer are covered by a polyethylene film which is not perforated.

Alternatively, in some embodiments of the present application, the second sound-absorbing layer is a sound-absorbing cotton soft felt made of polypropylene/PET two-component sound-absorbing cotton, and the second sound-absorbing layer and the sound-insulating layer are covered by a glue layer or an ultrasonic spot welding process.

Alternatively, in some embodiments of the application, the sound absorbing cotton mat has an areal density of 200gsm, the microfiber stiff felt and the first microfiber soft felt have an areal density of 1300gsm, and the polyethylene film has an areal density of 100gsm.

Optionally, in some embodiments of the present application, the second sound absorbing layer is a second ultrafine fiber soft felt, both the second ultrafine fiber soft felt and the first ultrafine fiber soft felt are made of the PET ultrafine fibers, and the second ultrafine fiber soft felt and the sound insulating layer are covered by the polyethylene film without perforation.

Alternatively, in some embodiments of the application, the areal density of the microfiber hard felt and the first microfiber soft felt is 1000gsm, the areal density of the second microfiber soft felt is 800gsm, and the areal density of the polyethylene film is 100gsm.

Optionally, in some embodiments of the application, 20% -40% of the low melting point PET is mixed with the PET superfine fiber.

Alternatively, in some embodiments of the application, the low melting PET is PET having a melting temperature of 100℃to 120 ℃.

In a second aspect of the present application, there is provided a method of manufacturing a sound absorbing and insulating pad for a vehicle, for manufacturing the sound absorbing and insulating pad for a vehicle, comprising the steps of:

preparing a sound insulation layer from PET superfine fibers mixed with low-melting PET, wherein the sound insulation layer is processed by a film pressing process;

covering one side of the sound insulation layer with a first sound absorption layer through a polyethylene film without holes, wherein the first sound absorption layer is a first superfine fiber soft felt, and the first superfine fiber soft felt and the superfine fiber hard felt are made of the same material;

and covering the other surface of the sound insulation layer with the second sound absorption layer.

Optionally, in some embodiments of the present application, before the sound insulation layer is processed by the film pressing process, the method further includes the following steps:

and preprocessing the PET superfine fibers into superfine fiber flat felt through an air-laying process.

Optionally, in some embodiments of the present application, the sound-insulating layer is covered with the first sound-absorbing layer by a polyethylene film that is not perforated, and includes the following steps:

covering a non-perforated polyethylene film on the first sound-absorbing layer, and then covering a sound-insulating layer on the non-perforated polyethylene film to form a three-layer structure of a sound-insulating layer, the non-perforated polyethylene film, and the first sound-absorbing layer;

heating the sound insulation layer, the polyethylene film without holes, and the first sound absorption layer in an environment of not less than 200 ℃ for 1-2 minutes;

and placing the sound insulation layer, the polyethylene film without holes and the first sound absorption layer into a die, maintaining the pressure, and cooling and forming.

Alternatively, in some embodiments of the present application, the second sound-absorbing layer is a second ultrafine fiber mat, and the second ultrafine fiber mat and the first ultrafine fiber mat are made of the same material, or are sound-absorbing cotton mats made of polypropylene/PET two-component sound-absorbing cotton.

Optionally, in some embodiments of the present application, when the second sound-absorbing layer is made of a sound-absorbing cotton mat made of polypropylene/PET two-component sound-absorbing cotton, the covering the other surface of the sound-insulating layer with the second sound-absorbing layer includes the steps of:

pre-cutting the sound-absorbing cotton soft felt;

and fixing the sound-absorbing cotton soft felt and the superfine fiber hard felt through an ultrasonic spot welding process or a hot melt adhesive process.

In a third aspect of the present application, there is provided a vehicle comprising the vehicle sound absorbing and insulating mat.

The application has the beneficial effects that:

the sound-insulating layer is made of the superfine fiber hard felt made of the PET superfine fibers mixed with the PET with the low melting point, so that the sound-absorbing and sound-insulating effects can be well realized, and meanwhile, the sound-insulating layer has the advantages of low odor and low VOC, and can be reduced by about 30 percent compared with the traditional sound-insulating layer;

through establishing to the mode of being connected by the PE membrane that does not punch between puigging and first sound absorbing layer, when realization superfine fiber soft felt that can be fine is connected with superfine fiber hard felt, because PE own fine sound insulation effect, when can further alleviate weight, increase the sound insulation effect of whole sound absorbing sound insulation pad, improve user experience.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are needed in the description of the embodiments will be briefly described below, it being obvious that the drawings in the following description are only some embodiments of the present application, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.

Fig. 1 is a schematic structural view of a sound absorbing and insulating pad for a vehicle according to the present application;

fig. 2 is a schematic structural view of yet another sound absorbing and insulating pad for a vehicle according to the present application;

FIG. 3 is a flow chart of a method of manufacturing a sound absorbing and insulating mat for a vehicle according to the present application;

fig. 4 is a flowchart of the present application for covering one side of the sound insulation layer with the first sound absorption layer through the polyethylene film without perforation.

Reference numerals:

100, superfine fiber hard felt; 200, a first superfine fiber soft felt; 300, a second superfine fiber soft felt; 400, a sound absorbing cotton soft felt; 10, PE film without perforations.

Detailed Description

The following description of the embodiments of the present application will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present application, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the application without making any inventive effort, are intended to fall within the scope of the application. Furthermore, it should be understood that the detailed description is presented herein for purposes of illustration and description only, and is not intended to limit the application. In the present application, unless otherwise indicated, terms of orientation such as "upper", "lower", "left", "right", "front", "rear" are generally used to refer to the directions of the upper, lower, left and right sides of the device in actual use or operation, and are specifically shown in the drawings.

It should be noted that the following description order of the embodiments is not intended to limit the preferred order of the embodiments of the present application. In the following embodiments, the descriptions of the embodiments are focused on, and for the part that is not described in detail in a certain embodiment, reference may be made to the related descriptions of other embodiments.

Example 1

Referring to fig. 1, the application provides a sound-absorbing and sound-insulating pad for a vehicle, which comprises a first sound-absorbing layer, a sound-insulating layer and a second sound-absorbing layer, wherein the second sound-absorbing layer and the first sound-absorbing layer are respectively fixedly arranged at two sides of the sound-insulating layer, the second sound-absorbing layer is a sound-absorbing cotton soft felt 400 made of PP (polypropylene)/PET (polyethylene terephthalate, commonly called polyester resin) double-component sound-absorbing cotton, the sound-insulating layer is a superfine fiber hard felt 100 made of PET superfine fibers, low-melting-point PET is mixed in the PET superfine fibers, the first sound-absorbing layer is a first superfine fiber soft felt 200 made of the same material as the sound-insulating layer, and the sound-insulating layer and the first sound-absorbing layer are bonded through a non-perforated PE (polyethylene) film.

Compared with the waste spinning felt, EVA, waste spinning felt structure, waste spinning felt, non-perforated high-gram-weight PE film and waste spinning felt structure in the prior art, the sound-absorbing and sound-insulating pad provided by the application has the advantages of low odor and low VOC (volatile organic compounds) while having stronger sound-absorbing and sound-insulating effects, and can reduce the weight by about 30% compared with the traditional type.

Specifically, the ultra fine fiber mat 100 of the soundproof layer is an ultra fine fiber PET mat, which is made by mixing 20% -40% of low melting point PET material with non-low melting point PET material, so that it has excellent "thermosetting property", i.e., does not rebound after cooling, for example, after mixing 20% -40% of low melting point PET material, it can be realized that the ultra fine fiber mat with a gram weight of 1500gsm is heated and then molded to a thickness of 2-3mm, forming the ultra fine fiber mat 100, and there is no fear that it will "rebound", i.e., thickness change with temperature decrease, so that it can bear soundproof effect, replace EVA and waste spun mat material, and compared with EVA material waste spun mat material, the ultra fine fiber PET material has better odor and VOC property; compared with the common automotive fiber (the common automotive fiber has the linear density of about 1.5-6D), the superfine fiber has high surface area to volume ratio, and can produce the automobile sound insulation pad with excellent sound absorption and insulation performance (the linear density of the superfine fiber is between 0.1-1.0D).

In addition, because the superfine fiber has lower linear density and is mixed with low-melting-point fibers, the superfine fiber can be hot-pressed to a very thin thickness, and compared with the traditional EVA, the EVA has the effect of reducing weight on the premise of not losing the sound insulation performance; in the aspect of preparation of the superfine fiber, the superfine fiber can be prepared by mixing PET, PP, PA and other materials, and the superfine fiber is preferably prepared by taking PET as a raw material. Meanwhile, PET has good creep resistance, fatigue resistance, abrasion resistance and dimensional stability, small abrasion and high hardness, and has the maximum toughness in thermoplastic plastics: good electrical insulation performance, little influence by temperature, but poor corona resistance, no toxicity, weather resistance, good chemical resistance stability, low water absorption rate, weak acid resistance and organic solvent resistance.

The low melting point PET fibers are PET materials having a melting temperature of 150 ℃ or lower, preferably 100 to 120 ℃, and more preferably about 110 ℃. It should also be understood that, for the scheme of the present application, only the low-melting-point PET material can be selected, and other materials cannot be selected, because the sound-insulating layer of the present application is composed of the ultra-fine-fiber PET hard felt, the composition thereof is only the low-melting-point PET material and the non-low-melting-point PET material, if the low-melting-point PET material is replaced with other materials, the sound-insulating layer of the present application is composed of the ultra-fine-fiber composite material, and besides the object characteristics of the whole material, such as the stretching rate, etc., parameters are greatly changed, the characteristics of air temperature, color, etc. are also changed.

Further, the first sound absorbing layer is a first ultrafine fiber soft felt 200, and the first ultrafine fiber soft felt 200 and the ultrafine fiber hard felt 100 are made of the same material, and also made by mixing 20% -40% of low melting point PET material with non-low melting point PET material, and the surface density is preferably 800gms.

As described above, the ultrafine fibers have better odor and VOC properties than the waste woven mats, so that the selection of the first sound-absorbing layer as the first ultrafine fiber mat 200 can better achieve sound-absorbing effect and effect of reducing volatile organic compounds of the material itself, and can also reduce the volume of the entire sound-insulating mat, optimizing the arrangement area.

It should be noted that, in actual vehicle engineering, there is no clear quantification standard, i.e. it does not have a standard that is "not so that it is very clear", generally in a sound-insulating material containing the same material of different thickness, a relatively soft material, i.e. it is defined as a soft felt, which acts as a sound-absorbing layer, and a relatively hard material, i.e. it is defined as a hard felt, which acts as a sound-insulating layer, for example, in the same material with an areal density of 1300gms, a material that is extruded to 3mm, a material that is extruded to 8mm is naturally relatively hard, which acts as a hard felt, and another as a soft felt, which acts as a sound-absorbing layer; in an alternative embodiment, one is extruded to 3mm and one is extruded to 2mm under the same material with an areal density of 1300gms, then the material extruded to 2mm is considered to be a hard felt as the sound insulating layer and the other is a soft felt as the sound absorbing layer.

Thus, in the solution of the application, there is not a very well defined demarcation for soft and hard mats, not just a material as a hard mat but not as a soft mat. The sound-insulating layer is made of a hard felt which is relatively hard to the other material, and the sound-insulating layer is made of a soft felt which is relatively soft to the other material.

Still further, the sound absorbing material of the present application preferably is a material capable of satisfying the sound absorbing coefficient of more than 0.3 in the 2000Hz frequency band at a thickness of 10mm, and at this time, the material satisfying the standard can achieve a sound absorbing effect better, and can be used as the first sound absorbing layer and/or the second sound absorbing layer in the scheme of the present application, otherwise, the material is not considered to have sound absorbing property, and cannot be used as the sound absorbing layer.

Still further, the first sound absorbing layer and the sound insulating layer are preferably connected through the PE film 10 without punching, and the benefit of connecting the first sound absorbing layer and the sound insulating layer through the PE film 10 without punching is that the PE film 10 without punching can be used as an adhesive between the superfine fiber PET soft felt of the first sound absorbing layer and the superfine fiber PET hard felt of the sound insulating layer on the one hand, and can well achieve the adhesion between the first superfine fiber soft felt 200 and the superfine fiber hard felt 100, and meanwhile, the PE film 10 without punching can be used as a supplement of the sound insulating layer through selecting the PE film 10 without punching, and is also a good sound insulating material due to the material characteristic of the PE film without punching, so that the sound insulating effect of the whole sound absorbing sound insulating pad is further improved, and the user experience is improved.

Preferably, the PE film has a preferred areal density of 100gms.

Still further, the first ultrafine fiber soft felt 200 in the first sound-absorbing layer and the ultrafine fiber hard felt 100 in the sound-insulating layer are manufactured by flat-plate felts manufactured by an air-laying process.

By selecting the air-laying process, the manufacturing cost can be well reduced, and the manufacturing efficiency can be improved. Meanwhile, the mechanical properties of the flat felt in all directions are relatively close, the lapping process is omitted, the manufacturing efficiency is improved, and the thickness of the fiber web is convenient to adjust.

Further, the second sound absorbing layer and the sound insulating layer are covered by an adhesive layer or an ultrasonic spot welding process.

It should be understood that, due to the material characteristics of the PP/PET two-component sound-absorbing cotton, the PP fiber is shrunk after being heated, so that the PP fiber cannot be thermally covered by a heating mode, and the problem that the PP/PET two-component sound-absorbing cotton cannot be thermally covered with other materials due to the problem of the PP/PET two-component sound-absorbing cotton can be well avoided by a glue layer or ultrasonic spot welding process, so that the PP/PET two-component sound-absorbing cotton can be covered with other materials.

Further, the sound-absorbing cotton felt 400 has an areal density of 200gms (gram weight per square meter), the ultra fine fiber hard felt 100 and the first ultra fine fiber soft felt 200 have an areal density of 1300gms, and the polyethylene film has an areal density of 100gms.

Example 2

The embodiment of the present application is different from embodiment 1 in that the second sound-absorbing layer of the embodiment of the present application is also made of the same material as the first ultrafine fiber soft felt 200, and the second sound-absorbing layer and the sound-insulating layer are also connected by the PE film 10 without perforation.

At this time, referring to fig. 2, the scheme of the present application is that the first superfine fiber PET soft felt-the non-perforated PE film 10-the superfine fiber hard felt 100-the non-perforated PE film 10-the second superfine fiber PET soft felt. The first sound-absorbing layer (the first ultrafine fiber soft felt 200) and the second sound-absorbing layer (the second ultrafine fiber soft felt 300) may or may not have the same surface density, and are preferably set to be different, for example, the first sound-absorbing layer has the surface density of 1200gms, the first sound-absorbing layer has the same surface density as the ultrafine fiber hard felt 100 of the sound-insulating layer, but has a different thickness (hardness), and the second sound-absorbing layer has the surface density of 200 gms.

Further, the surface density of the ultra fine fiber hard felt 100 and the first ultra fine fiber soft felt 200 is 1000 gms, the surface density of the second ultra fine fiber soft felt 300 is 800gms, and the surface density of the polyethylene film is 100gms.

It can be seen that, in this embodiment, since the second sound-absorbing layer is selected as the second superfine fiber soft felt, and the second superfine fiber soft felt and the first superfine fiber soft felt are both made of the PET superfine fiber, this results in that in this embodiment, the shape of the second sound-absorbing layer is not flat as described in embodiment 1, and further, the preferred application scenario of embodiment 1 is slightly different from that of this embodiment, in a specific embodiment, embodiment 1 is preferably applied to sound insulation of a vehicle chassis and a seat, the second sound-absorbing layer is disposed on a side close to the vehicle interior, so that the process difficulty and the manufacturing cost can be reduced, and embodiment 2 is preferably applied to noise treatment of a vehicle interior, for example, a vehicle engine, because there is not high requirement on the material shape of the sound-absorbing sound-insulating pad, and the manner of embodiment 2 can be better implemented.

Referring to fig. 3-4, the present application further provides a method for manufacturing a sound absorbing and insulating pad for a vehicle, which comprises:

s100: processing the sound insulation layer by a film pressing process, wherein the sound insulation layer is made of superfine fibers mixed with low-melting-point PET fibers;

before the sound insulation layer is processed by a film pressing process, superfine fibers can be pretreated by an air-laid process to prepare a superfine fiber flat felt, the superfine fiber surface density is preferably 1300gms at the moment, then the superfine fiber flat felt is manufactured by a heating film pressing process, and the thickness of the flat felt is further compressed to be 2-3mm, so that the superfine fiber hard felt is formed.

When the pretreatment is carried out by the air-laying process, the carded superfine fibers are separated from the carding component by utilizing air flow to form a fiber web, and the basic method is that the carded superfine fibers are stripped off (blown, sucked or blown and sucked) by utilizing the air flow under the centrifugal force of the carding component (such as a cylinder or a licker-in rotating at high speed), and the dispersed single superfine fibers are gradually deposited on a roller or a net curtain with small holes to form the fiber web due to the diffusion and the speed reduction of the air flow. The flat felt manufactured by the air-laid process is characterized in that superfine fibers in the fiber web are arranged randomly, so that the mechanical properties of the flat felt in all directions are relatively similar, meanwhile, the air-laid process can omit the lapping process, so that the manufacturing efficiency is improved, and meanwhile, the thickness of the fiber web is convenient to adjust.

Meanwhile, in order to increase the degree of disorder of the arrangement of the ultrafine fibers in the final web in the air-laying process, the conveying pipeline is often structured by using a venturi. The cross-sectional areas of any two sections in the venturi tube are unequal, the pipeline is gradually expanded from the inlet to the outlet, and as the fiber has a certain length, in the venturi tube, the head and tail ends of the fiber are positioned in two different sections, so that the head and tail ends of the fiber have different speeds, the head speed is lower than the tail end speed, the fiber changes direction to form a disordered arrangement, the fiber in the airflow-formed fiber net is in a three-dimensional disordered arrangement, and the final product is basically isotropic.

When the ultra fine fiber flat plate is manufactured into the ultra fine fiber hard felt by the film press molding, as described above, since the ultra fine fiber hard felt is made of the low melting point PET material mixed with 20% -40%, it can have excellent "thermosetting property", realize that the ultra fine fiber felt with the gram weight of 1500gsm is heated and then is molded to the thickness of 2-3mm, form the ultra fine fiber hard felt, so that it can take on the sound insulation effect, replace EVA and waste spinning felt materials,

s200: covering one side of the sound insulation layer with a first sound absorption layer through a PE film without holes, wherein the first sound absorption layer is a first superfine fiber soft felt;

when the first superfine fiber soft felt of the first sound absorbing layer is manufactured, superfine fibers can be pretreated through an air-laid process, but the sound absorbing material is manufactured, the sound absorbing function can be well achieved by the fact that the surface density of the sound absorbing material is preferably 800gms, and the first superfine fiber soft felt manufactured through the air-laid process is uniform in all aspects, has a large number of porous structures and is obvious in sound absorbing effect.

It can be seen that the manufacturing cost can be well reduced and the manufacturing efficiency can be improved by manufacturing the first sound absorbing layer and the sound insulating layer through the air-laying process.

For the PE film which is not perforated, the surface density is preferably 100gsm, so that the adhesion between the first sound absorption layer and the sound insulation layer can be well realized, and meanwhile, the sound insulation efficiency is improved.

Further, in step S200, this is achieved by:

s210: the non-perforated PE film is covered on the first sound-absorbing layer, and then the sound-insulating layer is covered on the non-perforated PE film, forming a three-layer structure of sound-insulating layer-non-perforated PE film-first sound-absorbing layer.

S220: the sound-insulating layer-unperforated PE film-first sound-absorbing layer is heated in an environment of not less than 200 ℃ for 1-2 minutes.

When the sound-insulating layer-non-perforated PE film-first sound-absorbing layer is subjected to heat treatment, the heat treatment is preferably performed by an oven, so that the sound-insulating layer-non-perforated PE film-first sound-absorbing layer is heated relatively uniformly, and in order to ensure that the heating temperature of the sound-insulating layer-non-perforated PE film-first sound-absorbing layer reaches 200 ℃, the temperature of the oven is preferably controlled to 200 ℃ to 280 ℃, so that the sound-insulating layer-non-perforated PE film-first sound-absorbing layer can be heated relatively efficiently.

S230: and placing the sound insulation layer, the PE film without holes and the first sound absorption layer into a die, maintaining the pressure, and cooling and forming.

S300: and covering the other surface of the sound insulation layer with the second sound absorption layer.

In the selection of the second sound-absorbing layer, the second sound-absorbing layer can be selected from a first superfine fiber soft felt which is the same as the first sound-absorbing layer, or can be selected from PP/PET double-component sound-absorbing cotton which is different from the first sound-absorbing layer, and when the second sound-absorbing layer is selected as the first superfine fiber soft felt, the manufacturing process and the manufacturing method are the same as the covering method of the first sound-absorbing layer and the sound-insulating layer.

At this time, it is necessary to form a five-layer structure of the second sound-absorbing layer-the PE film without perforation-the sound-insulating layer-the PE film without perforation-the first sound-absorbing layer first, then heat it at 200 ℃ for 1-2 minutes, then put it into a mold, hold the pressure, cool it and shape it.

When the second sound absorbing layer is selected as PP/PET double-component sound absorbing cotton, the second sound absorbing layer is made of a non-molded flat plate material, so that a cutting die is needed to be used for pre-cutting through holes and edges of parts, and then the second sound absorbing layer and the preformed soft and hard felt sound insulating pad are covered by ultrasonic spot welding or hot melt adhesive.

Table 1-4 shows the comparison of the sound absorption and insulation effects of the present application with the conventional AB type (waste felt + PE + PU) and double-layer dissipative structure AB type (ultra fine fiber).

Table 1 shows the sound insulation performance (insertion loss) of a flat sheet material at a thickness of 20mm, in comparison with 200g of a smPP/PET sound absorbing cotton mat, 1200g of a superfine fiber hard mat, 100g of a non-perforated PE film, 1200g of a first superfine fiber mat, and 600g of a waste spun mat, 900g of a PE film, 65kg/m3 of PU foamed in accordance with the present application. The laboratory tested was a reverberation-total elimination laboratory, and the laboratory tested was the same laboratory.

，

Table 1:200g of the smPP/PET sound-absorbing cotton soft felt, 1200g of the superfine fiber hard felt, 100g of the non-perforated PE film, 1200g of the first superfine fiber soft felt, 600g of the waste spun felt, 900g of the PE film, 65kg/m3 of PU were foamed, and the sound-insulating property (insertion loss) of the flat plate material at a thickness of 20mm was obtained.

It can be seen from comparison that the inventive sound insulation performance is weaker than that of the conventional ABA type at the low frequency of 400HZ, and that the inventive sound insulation performance is better than that of the conventional ABA type at other frequencies.

In the vehicle field, the main isolation noise is middle-high frequency noise, namely, the special use scene limited by the scheme of the application is a vehicle, and the sound absorption effect of the application is superior to that of the traditional ABA sound insulation scheme.

Table 2 shows the sound absorption performance of 200g of the smPP/PET sound absorbing cotton soft felt, 1200g of the superfine fiber hard felt, 100g of the non-perforated PE film, 1200g of the first superfine fiber soft felt, 600g of the waste spun felt, 900g of the PE film, 65kg/m3 of PU foam, and a flat plate material with the thickness of 20mm is compared, and the test laboratory is an alpha cabin.

，

Table 2:200g of the smPP/PET sound-absorbing cotton soft felt, 1200g of the superfine fiber hard felt, 100g of the non-perforated PE film, 1200g of the first superfine fiber soft felt, 600g of the waste spinning felt, 900g of the PE film, 65kg/m3 of PU are foamed, and the sound-absorbing performance of the flat plate material with the thickness of 20mm is compared.

It can be seen that the sound absorption effect of the scheme of the application is significantly higher than that of the conventional ABA type in each frequency band. Because the linear density of the single fiber of the superfine fiber is smaller, the superfine fiber has larger porosity compared with the coarse fiber after being pressed into felt, and the surface sound absorption of the superfine fiber is obviously better than that of the coarse fiber or waste spinning felt.

Thus, as can be seen from tables 1 and 2, the inventive solution is far better than the conventional ABA-type solution in terms of sound absorption effect and sound insulation effect, and has good acoustic performance. Meanwhile, the fiber ABA material has the advantages of low odor and low VOC, and compared with the traditional ABA type, the fiber ABA material can reduce the weight by about 20 percent, and saves the arrangement space.

In addition, it should be noted that the ABA structure of the present application is not identical to the double-layer dissipative (a-B) structure, and the research direction and research path are greatly different, and under the double-layer dissipative structure, if the hard layer is compressed to be thinner, the sound absorbing performance is significantly reduced, and if the hard layer is compressed to be thicker, the sound insulating performance is significantly reduced, so that tables 3-4 compare the schemes of the present application with the double-layer dissipative structure for illustrating the difference.

Table 3 shows the sound insulation performance (insertion loss) of a flat sheet material of 20mm in thickness for a 200g of the smPP/PET sound absorbing cotton mat +1200g of the ultra fine fiber hard mat +100g of the non-perforated PE film +1200g of the first ultra fine fiber mat compared with a 1400g of the ultra fine fiber hard mat +100g of the non-perforated PE film +1200g of the first ultra fine fiber mat. The laboratory tested was a reverberation-total elimination laboratory, and the laboratory tested was the same laboratory.

，

Table 3:200g of the smPP/PET sound-absorbing cotton soft felt, 1200g of the superfine fiber hard felt, 100g of the non-perforated PE film, 1200g of the first superfine fiber soft felt, 1400g of the superfine fiber hard felt, 100g of the non-perforated PE film, 1200g of the first superfine fiber soft felt, and the thickness of the flat plate material (insertion loss) is 20 mm.

Compared with a soft and hard felt (AB) type, the ABA type sound-absorbing and sound-insulating pad provided by the application has a sound-absorbing effect superior to that of a soft and hard felt-shaped device in a full frequency range, namely, the ABA type sound-absorbing and sound-insulating pad provided by the application has a better sound-insulating effect compared with a double-layer dissipation type structure.

Table 4 shows the sound absorption effect of a flat sheet material of 20mm in thickness for 200g of the PP/PET sound absorbing cotton felt, 1200g of the ultra fine fiber hard felt, 100g of the non-perforated PE film, 1200g of the first ultra fine fiber felt, 1400g of the ultra fine fiber hard felt, 100g of the non-perforated PE film, 1200g of the first ultra fine fiber felt, and alpha cabin.

，

Table 4: the sound absorbing effect of the flat plate material with the thickness of 20mm is achieved by 200g of the smPP/PET sound absorbing cotton soft felt, 1200g of superfine fiber hard felt, 100g of non-perforated PE film, 1200g of first superfine fiber soft felt, 1400g of superfine fiber hard felt, 100g of non-perforated PE film, 1200g of first superfine fiber soft felt.

Comparison As can be seen from the comparison of the data, if the multi-layer ABA type structure and the double-layer dissipative (soft and hard felt) structure are prepared by adopting the superfine fibers with the same surface density, the multi-layer ABA type structure has enhanced sound absorption and sound insulation compared with the double-layer dissipative (soft and hard felt) structure. As the ABA type material adopts superfine fibers, the pressed thickness is thinner, so that the sound insulation performance is better, and as the loose superfine fiber soft layer is arranged on the surface of the material, the surface sound absorption performance is better. Meanwhile, the design of the multi-layer ABA structure overcomes the problem that the sound absorption performance is obviously reduced if the hard layer is compressed to be thinner, and the sound insulation performance is obviously reduced if the hard layer is compressed to be thicker, namely the sound absorption effect and the sound insulation effect are not compatible.

Of course, the application also provides a vehicle, comprising the vehicle sound-absorbing and sound-insulating pad.

While the foregoing has described in detail the aspects of the present application, specific examples have been presented herein to illustrate the principles and embodiments of the present application, the above examples are provided solely to assist in the understanding of the methods of the present application and their core concepts; meanwhile, as those skilled in the art will have variations in the specific embodiments and application scope in accordance with the ideas of the present application, the present description should not be construed as limiting the present application in view of the above.

Reference throughout this specification to "one embodiment," "an embodiment," or "a particular embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment, and not necessarily all embodiments, of the present application. Thus, the appearances of the phrases "in one embodiment," "in an embodiment," or "in a specific embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics of any specific embodiment of the present application may be combined in any suitable manner with one or more other embodiments. It will be appreciated that other variations and modifications of the embodiments of the application described and illustrated herein are possible in light of the teachings herein and are to be considered as part of the spirit and scope of the application.

It will also be appreciated that one or more of the elements shown in the figures may also be implemented in a more separated or integrated manner, or even removed because of inoperability in certain circumstances or provided because it may be useful depending on the particular application.

In addition, any labeled arrows in the drawings/figures should be considered only as exemplary, and not limiting, unless otherwise specifically indicated. Furthermore, the term "or" as used herein is generally intended to mean "and/or" unless specified otherwise. Combinations of parts or steps will also be considered as being noted where terminology is foreseen as rendering the ability to separate or combine is unclear.

Claims

1. The sound absorption and insulation pad for the vehicle comprises a first sound absorption layer, a sound insulation layer and a second sound absorption layer, wherein the first sound absorption layer and the second sound absorption layer are respectively and fixedly arranged on two sides of the sound insulation layer, and the sound absorption and insulation pad is characterized in that the sound insulation layer is made of superfine fiber hard felt made of PET superfine fibers, the linear density of the superfine fibers is between 0.1 and 1.0D, and the linear density of the superfine fibers is between 0.1 and 1.0D, wherein the two sides of the sound insulation layer are respectively and fixedly arranged on the two sides of the sound absorption layer

The PET superfine fiber is mixed with a low-melting-point PET fiber.

2. The sound absorbing and insulating mat of claim 1, wherein said first sound absorbing layer is a first superfine fiber mat, said first superfine fiber mat being a mat made of said PET superfine fibers, wherein

3. The sound absorbing and insulating mat for a vehicle according to claim 2, wherein the second sound absorbing layer is a sound absorbing cotton blanket made of polypropylene/PET two-component sound absorbing cotton, and the second sound absorbing layer is bonded with the sound insulating layer by a glue layer or an ultrasonic spot welding process.

4. A sound absorbing and insulating mat according to claim 3, wherein said sound absorbing cotton mat has an areal density of 200gsm, said superfine fiber stiff felt and said first superfine fiber mat have an areal density of 1300gsm, and said polyethylene film has an areal density of 100gsm.

5. The sound absorbing and insulating mat of claim 2, wherein said second sound absorbing layer is a second superfine fiber mat, said second superfine fiber mat and said first superfine fiber mat are both made of said PET superfine fibers, and said second superfine fiber mat and said insulating layer are laminated through said non-perforated polyethylene film.

6. The sound absorbing and insulating mat for a vehicle of claim 5, wherein said superfine fiber stiff felt has an areal density of 1000gsm with said first superfine fiber soft felt, said second superfine fiber soft felt has an areal density of 800gsm, and said polyethylene film has an areal density of 100gsm.

7. A sound absorbing and insulating mat according to claim 1, wherein said PET superfine fibers are blended with 20% -40% of low melting point PET.

8. The vehicle sound absorbing and insulating mat according to claim 7, wherein said low melting point PET is PET having a melting temperature of 100 ℃ to 120 ℃.

9. A method of manufacturing a vehicle sound absorbing and insulating mat according to any one of claims 1 to 8, comprising the steps of:

10. The method of manufacturing a sound absorbing and insulating mat for a vehicle according to claim 9, further comprising the steps of, before processing the insulating layer by a film pressing process:

11. The method of manufacturing a sound absorbing and insulating mat for a vehicle according to claim 9, wherein the sound insulating layer is laminated on one surface thereof with the first sound absorbing layer through a polyethylene film which is not perforated, comprising the steps of:

12. The method of manufacturing a sound absorbing and insulating mat for a vehicle according to claim 11, wherein the second sound absorbing layer is a second ultrafine fiber mat made of the same material as the first ultrafine fiber mat or a sound absorbing cotton mat made of polypropylene/PET two-component sound absorbing cotton.

13. The method of manufacturing a sound absorbing and insulating mat for a vehicle according to claim 12, wherein when the second sound absorbing layer is made of a sound absorbing cotton mat made of polypropylene/PET two-component sound absorbing cotton, the step of covering the other surface of the sound insulating layer with the second sound absorbing layer comprises the steps of:

pre-cutting the sound-absorbing cotton soft felt;

14. A vehicle comprising a vehicle sound absorbing and insulating mat according to any one of claims 1 to 9.